Slow and wobbly wrote:...... Example: if the chain has play of 40mm when axle is loose then dont be surprised to find that it may only have 35mm of movement when axel is tightened because the axle has moved rearward from the adjusters as the swingarm clamps the wheel spacers.
You should never check the chain tension with a loose axle in the first place. It defeats the purpose straight away.....
Once you have adjusted the chain tension to the correct amount, then your chain tensioner 'blocks' or 'nuts' (as the case may be), should be seated firmly, and when you tighten up the axle nut, there should be *absolutely* no movement of the axle 'rearwards' as you indicate - if there is, you are doing the procedure incorrectly. ie - don't pull 'back' on the spanner, turn it around and push it 'forward' to tighten......
As far as 'loading' the suspension is concerned, if you are able to, then it should always be done with you sitting on the bike, in your normal riding gear - yeh I know this is difficult, and you need 4 arms as long as a gorilla to do everything

, but it *should* be done this way - it ensures that the 'loaded' amount of freeplay in the chain will cope with any bumps in the road, and not over-tighten during suspension movement. ( which is the whole reason for free-play in the first place.)
If you cannot set free-play with the help of someone esle, then just set it up towards the 'higher' end of the range, and check it when someone is there to help.
(sorry for long post)
